ISO50001 - ISO50001... · objective, but ISO 50001 gives tools that empower you to be more disciplined…

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  • ACTSYS Process Management Consultants Pte LtdACTSYS Process Management Consultants Pte Ltd

    ISO50001 Barriers to Adoption by Industry

    October 2016

    1

  • ACTSYS Process Management Consultants Pte Ltd

    Operator = Me

    Energy Manager = My Wife

    Energy Inefficiency = Not very visible

    Energy Inefficiency KPI = # Pails/Day

    Energy Audit = The Pail

    Energy Planning = Wifes household review

    Putting pail in place

    Setting KPI target

    Energy Improvement = Repair Tap

  • ACTSYS Process Management Consultants Pte Ltd

    ISO 50001 Energy Mgmt System

    Overview of Requirements Based on the Plan-Do-Check-

    Act continual improvement framework Plan: establish the objectives and

    processes necessary to deliver results in accordance with opportunities to improve energy performance and the organization's policies

    Do: implement the processes

    Check: monitor and measure processes and product against policies, objectives and the key characteristics of its operations and report the results.

    Act: take actions to continually improve energy performance.

  • ACTSYS Process Management Consultants Pte Ltd

    Global Growth of ISO50001

  • ACTSYS Process Management Consultants Pte Ltd

    High Growth Countries

    Germany Energy intensive industries (>5 GWh/Y) minimum

    requirement ISO50001 certification for energy tax incentives and partial exemption from renewable levies

    Mandatory Energy Audits

    3500 ISO50001 certifications (2014)

    Sweden Large Industries mandatory Energy Audits by certified

    energy auditor

    Obligatory Implementation of certified Energy Management System

  • ACTSYS Process Management Consultants Pte Ltd

    ISO50001 in Singapore

    Limited number of companies have gone for certification (

  • ACTSYS Process Management Consultants Pte Ltd

    Sustaining Energy Performance

    50%

    40%

    60%

    30%

    10%

    10%

    30%

    70%

    50%

    30%

    10%

    30%

    Energy Manager

    Energy Plannning

    Energy Measurement

    Energy Reporting

    Energy Targets

    Energy Performance Indicators

    Energy Deviation Monitoring

    Energy Audits

    Equipment Performance

    Energy Improvement activities(Process and maintenance)

    Energy Training

    Continuous Improvement

    ISO50001 EnMS Gap Analysis

  • ACTSYS Process Management Consultants Pte Ltd

    Singapore ECA Findings

    Energy Conservation Act covered 213 energy intensive facilities

    Findings over 2 years of Reporting Varying levels of rigour in Energy Management

    Low level of ambition in Energy Efficiency Improvement

    Room for improvement in Energy Efficiency

    62% of Energy Performance of major systems not tracked

    Over 50% measured less than 1/3 of important parameters

    Source : NEA

  • ACTSYS Process Management Consultants Pte Ltd

    Actsys Observations

    Customer Segments

    Refineries

    Petrochemical Plants

    Pharmaceuticals

    Semiconductor

    Food Industry

    Energy Audits

    Measurement and Verifications

    Regular Performance Monitoring

  • ACTSYS Process Management Consultants Pte Ltd

    Observation of Common Gaps

    Energy Planning (4.4)

    No Energy Reviews / Audits (4.4.3)

    Lack of internal capacity

    Not considered use of external Energy Auditors

    No structured plan for improvement

    No Energy Baseline (4.4.4)

    Not established without Energy Review

    Inadequate Energy Performance Indicators (4.4.5)

    Usually no Plant Wide EnPI (and no KPI targets)

    Not normalized for production levels or ambient conditions

  • ACTSYS Process Management Consultants Pte Ltd

    Observation of Common Gaps

    Implementation and Operation (4.5)

    Operational Control (4.5.4)

    No targets given to adjust for energy efficiency

    No criteria available to trigger maintenance for energy efficiency

    Design (4.5.6)

    Often farmed out to EPC contractors or Equipment Suppliers who do not place high priority on energy efficiency features

  • ACTSYS Process Management Consultants Pte Ltd

    Observation of Common Gaps

    Checking Performance (4.6)

    Measurement, Monitoring and Analysis (4.6.1)

    Insufficient instrumentation

    None or disparate data logging systems eg flows, temps on Scada and motor power on Motor Control Centre Panel

    Incomplete comprehension which operating parameters contribute to energy performance egChiller Condenser sub-cooling

  • ACTSYS Process Management Consultants Pte Ltd

    Inconvenient Truth

  • ACTSYS Process Management Consultants Pte Ltd

    Amine treating of Gas flows to

    remove H2S, CO2 etc Absorber column

    Regenerator column

    Loss of Energy Efficiency Excessive amine circulation

    rates Pumping energy

    Regenerator reboiler heat

    Regenerator Reboiler heat

    Case Study - Absorber Optimization

  • ACTSYS Process Management Consultants Pte Ltd

    Proposed

    operating point Current operating

    point

    Case Study - Absorber Optimization

  • ACTSYS Process Management Consultants Pte Ltd

    Energy Management Dashboards

    Enabler for ISO50001 integration into organization

    Many varieties commercially available

    Important features

    Plant Wide Energy KPI vs Target

    Drill down into plant subsections

    Drill down into equipment level operating parameters

  • ACTSYS Process Management Consultants Pte Ltd

    Energy Consumption Dashboard

  • ACTSYS Process Management Consultants Pte Ltd

    ISO50001 DashboardRefinery A

    Overview Refinery EII 82 102.4

    Crude Dis ti l ler Unit 1 CDU1 Delta +15.2

    Crude Dis ti l ler Unit 2 CDU2 Delta -2.5

    Naphtha Hydrotreater NHT Delta -4.1

    Cont Catalytic Reformer CCR Delta +3.4

    Gasoi l Hydrodesulphuriser GO HDS Delta +2.1

    High Vacuum Unit HVU Delta -1.5

    Hydrogen Manuf Unit HMU Delta -4.5

    Hydrocracker HCU Delta +3.2

    Delayed Coker Unit DCU Delta -2.8

    Cogen Unit COGEN Delta +4.8

    Uti l i ties UTILS Delta +7.1

    30/7/2016 16:48Energy Performance Dashboard

  • ACTSYS Process Management Consultants Pte Ltd

    Operational Dashboard

    Refinery A

    Actual Target Contribution to Refinery EII

    Overview CDU 1 EII 155.1 122 +15.2

    Crude Distiller Unit 1 CDU Intake m3/h 347.1 351 +1.0

    Crude Distiller Unit 2 F101 Stack Temp DegC 288 285 +0.0

    Naphtha Hydrotreater F101 Excess O2 % 2.4 1.8 +0.29

    Cont Catalytic Reformer C101 Stripping Stm % 2.8 3 -1.15

    Gasoil Hydrodesulphuriser C101 Pressure kg/cm2g 1.45 1.45 +0.0

    High Vacuum Unit C119 Stripping Stm % 3.8 3 +2.3

    Hydrogen Manuf Unit C103 Reboil Ratio kJ/kg 144 300 -2.1

    Hydrocracker C102 Reboil Ratio kJ/kg 32 45 -0.3

    Delayed Coker Unit C109 Reboil Ratio kJ/kg 486 300 +4.3

    Cogen Unit C110 Reboil Ratio kJ/kg 137 140 -0.5

    Utilities C110 Pressure kg/cm2g 8 8 +0.0

    CDU Preheat Train HX UA

    E137 kW/C 257 260 +0.0

    E105A/B kW/C 52 116 +1.2

    E139 kW/C 31 20 -0.1

    E142A/B kW/C 106 212 +2.4

    E108A/B kW/C 65 123 +3.5

    E112A/B kW/C 180 220 +2.2

    E141 kW/C 492 318 -0.24

    E136 / E140 kW/C 120 300 +2.4

    Energy Performance Dashboard 10/9/2016 12:02

  • ACTSYS Process Management Consultants Pte Ltd

    Heres why we need dashboards

  • ACTSYS Process Management Consultants Pte Ltd

    0.00

    2.00

    4.00

    6.00

    8.00

    10.00

    12.00

    14.00

    -

    1,000,000.00

    2,000,000.00

    3,000,000.00

    4,000,000.00

    5,000,000.00

    6,000,000.00

    7,000,000.00

    8,000,000.00

    Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12 May-13

    Ene

    rgy

    Co

    st, R

    M

    ESC

    , mm

    BTU

    /MT

    MTBE Energy Specific Consumption & Energy Cost (2008-2012)

    Energy Cost

    MTBE EnergySpecificConsumption

    Savings

    RM 2

    Million/month

    Case Study - Energy Index Dashboard

  • ACTSYS Process Management Consultants Pte Ltd

    Learning Points from Others

    3M 3M_Global.pdf

    EE program already in place 40 years

    ISO50001 gave tools for continuous improvement

    Implemented ISO50001 since 2011 in 18 facilities in 7 countries, they show EE improvement 60% more than group average

    Abbott Abbott.pdf

    Deciding Energy Performance Indicators and putting in place metering plan

    We should have done it earlier

    3M_Global.pdfAbbot.pdf

  • ACTSYS Process Management Consultants Pte Ltd

    Learning Points from Others

    JK Lakshmi Cement Ltd JK Lakshmi.pdf

    Many years of Energy Management activities but ISO50001 provided structure

    Smooth implementation of ISO50001 as staff already well versed with ISO9001 and ISO14001

    Challenge was to involve bottom line workmen

    JK Lakshmi.pdf

  • ACTSYS Process Management Consultants Pte Ltd

    Learning Points from Others

    Nissan USA Nissan_USA.pdf

    ISO50001 adds rigor, analysis, and gives good guidance. Its one thing to have a target and objective, but ISO 50001 gives tools that empower you to be more disciplined and prove the impact certain activities have. Nissan North America Energy Team

    Some believed the company had already seized all opportunities to reduce energy usage; however, the EnMS and the EnPI tool enabled discovery of correctable, previously undetected energy losses.

    Nissan_USA.pdf

  • ACTSYS Process Management Consultants Pte Ltd

    Learning Points from Others

  • ACTSYS Process Management Consultants Pte Ltd

    Thank You

    GT

    SH

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    LP TURB POWER (10.87%)

    CONDENSER LOSS 33.53%

    SHAFT POWER

    IP TURB POWER (6.68%)

    AU

    XIL

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    ROTOR COOLING LOSS (2.09%)

    COMBUSTOR LOSS (0.49%)

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    DUCT

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    RADIATION LOSS

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    PIP

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    )

    LP STEAM (4.03%)STACK LOSS (8.97%)

    IP STEAM (8.6%)

    CHEMICAL

    ENERGY

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    RADIATION LOSS (0.06%)

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    www.actsys.com

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